LDB Spec

Tender Document for Nigahi CHP Phase-II (Package A)
Specification No. SP/E-17

SPECIFICATION FOR 415V/240V LIGHTING DISTRIBUTION BOARD
1.0
SCOPE
This specification covers requirements for 415V/240V Miniature and/or Residual
Current Circuit Breaker suitable for installation in a switchboard (LDB).
The Miniature-Residual Current circuit breaker shall comply with the latest
revision of IS : 8828 and the associated switch board shall conform to IS : 8623
with the relevant parts of standards mentioned in clause 2.0 except where
modified or extended by the provision of this specification.
Any material and component not specifically stated in this specification but
necessary for trouble free operation of the equipment and accessories specified
herein shall deemed to be included.
2.0
OTHER RELEVANT STANDARDS

The other relevant indian standards are as under :
IS : 3043 : Code of practices for earthing.
IS : 4237 : General requirements for switchgear and controlgears for voltages
not exceeding 1000V AC.
IS : 10118 : Code of practice for selection, installation and maintenance of
Switchgear and Controlgear.
IS : 11353 : Guide for uniform system of marking and identification of
conductors and apparatus terminals.
IS : 8588 : Thermostatic bimetals
In case equipments conforming to other standards like BS, DIN, VDE, ANSI, JIS
or other standards are offered the same shall be considered if these ensure
performance equivalent or superior to Indian standards.
The equipment covered under this specification shall comply with all the latest
applicable statutory rules, regulations, acts and safety codes which may be in
force during the period of execution and which are related with design,
construction and operation of equipment in the locality where the equipment is to
be installed.
Nothing in this specification shall be construed as to relieve the supplier of the
responsibility for correctness of the design and construction of the equipment.
All the standards being followed shall be listed out in the bid. Where any foreign
standard is being followed, the copy of the same shall be provided with the bid.
Wherever service conditions and requirements laid down in this specification
differ from applicable standards, the conditions specified herein shall prevail.
Vol-II / Sec.-IV.2 / Page - 143
3.0
SERVICE CONDITIONS
Ambient temperature
Maximum 500C.
Altitude
Upto 1000 M above MSL.
Relative Humidity
Approximately 97 %.
Pollution degree
Degree 4 as per IS : 13947 (Part I)

(i.e. the pollution generates persistent
conductivity caused by conductive dust)
4.0
CONSTRUCTION
4.1
General
The miniature circuit breakers shall be suitable for mounting in 4 ways/8 ways/ 12
ways/16 ways distribution boards with IP-42 protection.
4.2
Enclosure
The enclosure shall be manufactured from at least 2 mm thick steel sheets in
aesthetically appealing powder coated finish. The boards are to confirm to the
requirement of IS : 8623 for factory built assemblies.
4.3
Bus bar system

The bus bar system should incorporate integral single piece bar and coupling
links to avoid chances of hot spot developing as is possible with bolted
construction of bus bar and links. The bus bar system should accept tripple pole,
double pole and single pole circuit breakers in any combination of these. The bus
bars should be shrouded against accidental contact. The circuit breakers should
be arranged in two horizontal or vertical banks with switch levers operating in
vertical or horizontal planes for on-off switching. The mounting of breakers
should be quick snap and easy removal type without disturbing the other
breakers. It should be capable of being connected to at least cable sizes of 25
mm2 for phase conductors and 16 mm2 for neutral conductors. Two conduit
entry plates at the top and the bottom should facilitate drilling of holes at site to
suit individual requirements.
4.4
Miniature/Residual Current Circuit Breakers and Distribution Boards
4.4.1 These breakers shall be current limiting devices with an inverse time delayed
thermal trip device and an undelayed magnetic trip device to take care of steady
overload and short circuit and earth leakage faults respectively. The breakers
shall be suitable for switching/control/protection/regulation of lighting, control and
motor circuits.
4.4.2 The circuit breakers should also be suitable for protection/control/switching of
three phase, 415 Volt motors upto 7.5 kW.
4.4.3 The technical data for Circuit breakers are given in Annexure-IA.
4.4.4 The technical data for Distribution Boards are given in Annexure-IB.
ANNEXURE IA
TECHNICAL SPECIFICATION FOR
MINIATURE /RESIDUAL CURRENT CIRCUIT BREAKERS
1
2
Applicable standard
Number of poles
: IS 8828
: 3 + N for incoming MCB and RCCB if
any.
3 + N/3/1 + N / 1 for outgoing for MCB.
Rated Current
: 0.5/1/5/10/16/25/32/40/63 A
Breaking capacity
: 9 kA
Rated voltage
Frequency
: 240 V for SPN / SP

415 V for TPN / TP
: 50 Hz
Enclosure of the breakers
: Moulded self extinguishing thermoset

plastic.
Dolly (Switching lever)
: Can be locked in either (Off or On

position).
Auxiliary contact poles (for

control circuits, if any)
10 Fixing
: 240V 5A, A.C. (Optional).
11 Terminals
: 25 mm2 conductors for phase and 16

mm2 for neutral.
12 Mechanical service life
: Not less than 20,000 operations.
13 Electrical endurance at rated

load
14 Climate resistance to confrm
requirements of
15 Ambient temperature
: Not less than 20,000 operations.
: Snap fitting
: IEC - 68/2
: As mentioned in para 3.0
ANNEXURE - IB
TECHNICAL SPECIFICATION FOR
DISTRIBUTION BOARDS
Applicable Standard
: IS : 8623
Bus current carrying capacity
: Suitable with TP + N.
Enclosure
: 2 mm thick CRCA sheets.
No. of outgoings
: 4 ways / 8 ways / 12 ways / 16 ways.
No. of incoming
: 1 No.
Mounting
: Channel mounted / Flush top cover.
Cable entry
: Top / Bottom cable entry conduits.
Protection
: IP 42 (Metallic double door) degree of

protection.
Finishing
: Powder coated finish.
10 Locking
: Pad locking facility.
11 Bus bar
: Shrouded type integral single piece bus

bar.
12 Arrangement of breakers
: Vertical/Horizontal arrays.

SPECIFICATION FOR SWITCH BOARDS FOR LIGHTING CIRCUITS
1.0
SCOPE:
This coveres requirements for switch boards for tube light & fan circuits .
2.0 CODES:
The applicable codes are as under:
IS : 1293
3-Pin, plug and socket outlets
IS : 3954
Switches for domestic and similar purposes
IS : 694
PVC unarmoured 660 V grade cable
IS : 5133
Boxes for enclosure of electrical accessories - Steel and cast iron

boxes
IS : 9224
Low voltage fuses
3.0 CONSTRUNCTION:
3.1 Switch Boards
i) The switch boards shall be made of 1.6 mm thick, MS sheet with 3 mm, thick
decorative, bakelite cover. The switch boards shall be hot dip galvanised and
provided with earthing terminal, mounting holes and screws, specified number of
conduit knock outs on both the sides etc. The switch boards shall be suitable for
surface mounting. The switchboards shall mount Piano Key switches and sockets .
ii)
The switches shall be Piano Key Type single pole, quick make quick break
suitable for operation on 230 V AC supply.
iii) The sockets shall be of 5 pin type 5/15 A, 230 V AC socket with 15 A switch.
iv) The switch boards shall be adequately sized to accommodate switches/fan
regulators/sockets. All switch boards mounted items shall be fully wired by 660 V
grade PVC insulated flexible Copper wire.
v) All in-coming and out-going wires shall be suitable for loop in loop out of 4 Sq. mm
stranded Aluminium wire and tap off of 1.5 Sq. MM copper wire.
ANNEXURE I
TECHNICAL INFORMATION
1.
Rated Voltage
230 V
2.
No of 5A piano key switches
As required
3.
No of 5/15A , 3/5 pin socket with 15A

switch
4.
No of fan regulators (electronic)
As required
5.
Rewirable fuse 5A with base
As required
6.
Top cover
Decorative Backelite 3 mm
thick
7.
Switch board
1.6 mm thick MS sheet
8.
Internal wiring
with 660 V grade by 1.5 Sq mm

Copper cable
9.
Mounting
Flush/projected
Two terminals shall be provided

for earthing by 8 SWG GI Wire
10. Earthing
As required

SPECIFICATION FOR LAMP FIXTURES
1.0
SCOPE
1.1
This specification covers requirement for fixtures of tubular fluorescent lamps,

sodium and mercury vapour lamps & tungsten lamps in various applications.
1.2
The fixtures shall comply with the latest revision of IS:1913, IS:3287, IS:4013,
IS:1777 & IS:10322 except where modified or extended by the provision of this
specification and with the relevant parts of standards mentioned in clause 2.0.
1.3
Any material, component or accessory not specifically stated in this specification

but necessary for trouble free operation shall deemed to be included.
2.0
2.1
The other standards applicable are as under :

IS :
1534 Ballasts for fluorescent lamps for switch start circuits
IS :
6616 Ballasts for high pressure mercury vapour lamps
IS : 1569 Capacitors for use in tubular fluorescent and high pressure
Vapour discharge lamp circuits
IS :
2215 Starters for fluorescent lamps
IS :
3323 Bi Pin lamp holders for tubular fluorescent lamps
IS :
7569 Case acrylic sheets for use in luminaires
IS :
8913 Methods of measurement of lamp cap. temperature rise
IS :
10276 Edison Screw lamp holders
IS :
3043 Code of practice for earthing
3.0
CONSTRUCTION
3.1
All lighting fixtures shall be complete with lamp holder, control gear, reflector and
cable gland. Power Factor of the fixtures shall be not less than 0.96. Suitable p.f.
correction capacitor shall be provided wherever required.
3.2
Fluorescent lamp fixtures
3.2.1 The single tube economy type fixtures of the batten type shall be made of M.S.
sheet finished in white stove enamel suitable for direct fixing to wall or ceiling.
The unit shall be complete with polyester filled choke, starter and lamp holders
with end covers.
3.2.2 The single/twin tube commercial type fixtures of the channel type shall be made
of cold rolled cold annealed (C.R.C.A.) M.S. sheets finished in white/grey stove
enamel suitable for direct fixing to wall or suspended from ceiling. The unit shall
be complete with polyester filled metal cased chokes, p.f. correction capacitor,
starter and rotor locking type lamp holders with end covers.
3.2.3 The twin tube decorative type fixtures with louvres of the hexagonal pattern shall
be supplied on a channel type fixture mentioned in para 3.2.2. The louvres
moulded in white thermoplastic compound shall be supported below the channel

by means of white stove enamelled metallic side pannels and black stove
enamelled metallic end plates. The unit shall be complete with polyester filled
chokes, p.f. correction capacitor, starter and rotor locking type lamp holders.
3.2.4 The single/twin decorative tube fixtures with diffusers shall be extruded in opal
thermoplastic compound and supported in black end plates. The diffuser shall be
supplied on a channel type fixture mentioned in para 3.2.2. The unit shall be
complete with polyester filled chokes, p.f. correction capacitor, starter and rotor
locking type lamp holders.
3.2.5 The twin tube recessed fixture with louvers shall be made in a single piece
moulding in white thermoplastic compound. The moulding shall be carried in a
single piece sheet steel housing wired completely with chokes, p.f. correction
capacitor, starter and lamp holders. The fitting shall be designed for recessing
into false ceiling and provided with a flange on all sides to ensure flush mounting.
The fixture shall be finished in high Quality stove enamelled white/grey outside
and white inside. The louvre shall be removable by tilting and lowering when
carrying out lamp replacement.
3.2.6 The twin tube recessed fixtures with opal diffuser shall be made in an opal acrylic
diffusing panel. The panel shall be carried in a single piece sheet steel housing
wired completely with chokes, pf. correction capacitor, starter and lamp holders.
The fitting shall be designed for recessing into false ceiling and provided with a
flange on all sides to ensure flush mounting. The fixture shall be finished in high
Quality stove enamelled white/grey outside and white inside. The diffuser panel
shall be easily removable for carrying out lamp replacement.
3.3
High bay/Medium bay fixtures for Vapour lamps.
3.3.1 The reflector shall be made of cast aluminium anodised and electrochemically
treated for brightness to give a concentrated light distribution.
3.3.2 The control gear shall comprise ballasts, p.f. correction capacitors, iguitor. The
control gear shall be housed adjacent to lamp holder housing. The lamp holder
housing shall have radial cooling fins for efficient heat dissipation.
3.3.3 Heat resistant gasket or suitable arrangement shall be provided between the
toughened glass and the reflector, between the lamp holder housing and the
reflector and between the top canopy and the control gear housing.
3.3.4 The reflector shall be attached to the lamp holder housing by slotted/ adjustable
strips for lowering/raising to carry out relamping.
3.3.5 A cable gland shall be provided on the side of the canopy.
3.3.6 The fixture shall be suspended by means of a suspension hook in the top of the
canopy. No chain suspension is acceptable.
3.3.7 The fixture shall be suitable for 1000 W HPMV lamp or 400 W HPSV lamp.
3.4
Highbay/Medium bay fixtures for emergency lighting
3.4.1 The reflector shall be made of cast aluminium anodised

3.4.2 The fixture shall be suitable for 500 Watt tungsten G.L.S. lamps
3.4.3 The top canopy and the lamp holder shall be made of cast aluminium
3.4.4 The cable entry shall be on the side of the canopy
3.4.5 The fixture shall be suspended by means of a suspension hook in the top of the
canopy. No chain suspension is acceptable.
3.5
Industrial Weather proof bulk head fixtures for conveyor Gantry lighting
and other areas
3.5.1 The fixtures shall be a single piece aluminium body finished in stove enamel grey
outside and white inside
3.5.2 The unit shall be supplied with a frosted glass, synthetic rubber gasket and a
lamp holder for 70 Watt SV lamps.
3.6
Flood light fixtures
3.6.1 The reflector shall be made of cast aluminium anodised and electrochemically
treated for birghtness and of parabolic shape to give a long beam throw.
3.6.2 A toughened front glass shall be sealed into the front of the fixture body with a
heat resistant
3.6.3 The fixture shall be suitable for 1000/400 Watt HPSV lamp or 1000 W halogen
lamp. The replacement of the lamp shall be done by opening a door/opening at
the back of the fixture body.
3.6.4 The cable entry gland shall be fitted to the lamp holder housing
3.6.5 A graduated disc shall be provided to enable adjustment in the spinning angle of
the fixture after mounting the fixture on a bracket.
3.6.6 The fixture shall be mounted on a bracket
3.7
Street light fixtures
3.7.1 The reflector shall be made of two cast aluminium anodised surfaces one on
either side.
3.7.2 A heat resistant prismatic bowl refractor shall be mounted on the reflector held
with a metal ring attached to the canopy by hinge and toggle catches.
3.7.3 The fixture incorporating reflector, control gear housing, lamp holder, terminal
block shall be made of one piece aluminium sheet deep drawn and finished silver
grey to resist corrossion.
3.7.4 The cable entry shall be from the side
3.7.5 A locking device shall be provided to prevent unauthorised opening of the fixture.
3.7.6 The fixture shall be suitable for mounting 70 Watt/80 Watt/125 Watt/250 Watt/
400 Watt lamps.
3.8
Street light fixtures for fluorescent lamp
3.8.1 The canopy shall be fabricated from aluminium sheets finished in gray sloving
enamel.
3.8.2 The control gear shall comprise p.f. correction capacitor, polyester filled chokes
and starters
3.8.3 The control gear and the lamp holder shall be internally wired to a terminal block.
3.8.4 A transparent bowl moulded from acrylic sheet shall be filled rigidly against a
heat resistant rubber gasket fixed to the canopy by suitable means making the
fixture dust & water proof.
3.8.5 The fixture shall be suitable for mounting on cantilevers having outside diameter
50 mm.
3.8.6 The fixture shall be suitable for Single/Twin tubes
3.9
Post top fixtures for tungsten GLS or Mercury Vapour lamps
3.9.1 A cast aluminium spigot cap shall carry an opal acrylic bowl secured to it by
screws
3.9.2 This spigot cap shall also carry the lampholder and a bridge piece supported on
two pillars.
3.9.3 An aluminium canopy shall be fixed to the bridge piece by screw to make the
whole fixture totally enclosed.
3.9.4 For fixtures with mercury vapour lamps, the control gear comprising choke,
ignitor and p.f. correction capacitor shall be housed in aluminium canopy.
3.9.5 The fixture shall also be suitable for 1000 Watt tungsten GLS lamp & 80
Watt/125 Watt mercury vapour lamp.
3.10
Street light fixture for low pressure sodium vapour lamps
3.10.1 The reflector shall comprise two electrochemically brightened and anodised
aluminium reflectors of curved sections
3.10.2 The reflector unit shall be housed inside cast aluminium canopy. The canopy
shall be curved to give full length support to the reflectors.
3.10.3 The reflector shall be totally enclosed by an acrylic bowl scaled on a heat
resistant rubber gasket.
3.10.4 All control gear components, i.e. ballast, p.f. correction capacitors and starters
shall be housed inside the canopy.
3.10.5 The canopy shall have a cable entry suitable for GI pipe with outside diameter 50
mm. The fixture shall be suitable for cantilever mounting on G.I. pipe.
3.10.6 The fixture shall be suitable for 135 Watt low pressure sodium vapour lamp
3.11
Mast top fixtures for vapour lamps
3.11.1 The reflector shall consist of an opal acrylic bowl secured to a cast aluminium
spigot on a aluminium frame-work. The reflector shall be enclosed by an
aluminium canopy.
3.11.2 The aluminium frame-work shall carry the lamp holders & control gear
components like ballasts and starters.
3.11.3 The p.f. correction capacitor & the HRC fuses shall be housed in a separate box
below the framework for easy replacement.
3.11.4 The aluminium frame-work shall be fixed to a G.I. pipe
3.11.5 The G.I. pipe shall be suitable for mounting on a mast 14 m/18 m long.
3.11.6 The fixture shall be suitable for 250 Watt HPSV/400 Watt HPMV lamps.
3.12
Chokes
3.12.1 The chokes shall conform to relevant Standards

3.12.2 The chokes shall be electronic type.
3.13
Capacitors
3.13.1 The capacitors shall conform to relevant standards

3.13.2 The capacitors shall be hermetically sealed in aluminium starters
3.13.3 For twin tube lights these should be connected for anti-stroboscopic effects.

SPECIFICATION FOR 415 V POWER RECEPTACLES
1.0
SCOPE
1.1
This specification covers the requirements for 415 V power receptacles

incorporating switches, sockets and plugs.
1.2
The receptacles shall comply with the latest version of IS 8623 except where
modified or extended by this specification and with the relevant parts of
standards mentioned in clause 2.0.
1.3

but necessary for trouble free operation shall be deemed to be included.
2.0
2.1
The other relevant standards applicable are as under :

IS :6875
Switches and push-buttons
IS :13703
LV fuses for voltages not exceeding 1000 V AC
IS :2147
Degree of protection provided by enclosures for low voltage
switchgear and control gear
IS :3043
Code of practice for earthing
IS :2629
Hot dip galvanising
IS :5082
Wrought Aluminium and Aluminium alloys for electrical purposes
IS :1248
Electrical Indicating instruments
IS :5
Colours for ready-mixed paints and enamels.
IS :1554
PVC insulated cables for working voltages upto and including
1100V
IS :2551
Danger Notice Plates
IE Rules
1956
2.2
Nothing in this specification shall be construed as to relieve the bidder of the

Wherever the service conditions and requirements laid in this specification differ
from the applicable standards, the conditions specified here in shall prevail.
Equipment complying with any other authoritative/internationally recognised
standards such as IEC, BS, VDE etc. shall also be considered if it ensures
performance equivalent or superior to Indian Standards. In such cases the bidder
shall clearly indicate the standard adopted and furnish a copy of the latest
version in english alongwith the bid and bring out the salient features for
comparison.
The standard specifications and code of practices referred to herein shall be the
latest edition including all applicable official amendments and revisions as
published one month prior to the date of opening of bids. In case of conflict
between this specification and those (IS Codes, Standards etc.) referred to
herein, the former shall prevail.
3.0
SERVICE CONDITION
3.1
a) Ambient air temperature
Maximum 50oC
b) Altitude
Upto 1000 Meters above MSL
c)
Heavily polluted with coal dust
3.2
Location
Operating Conditions
a) Nominal system voltage
415 V ( + 10%)
b) Supply frequency
50 Hz (-5% to +3%)
c) System earrthing
Effectively earthed
d) Highest fault level
9 kA
4.0
DESIGN
4.1
Electrical
The receptacle shall be designed to ensure the following :
(i) Continuous operation at rated capacity at service condition already mentioned

(ii) Capacity to withstand fault level already mentioned .
4.2
Mechanical
The receptacle shall be designed to ensure the following :
(i) Ready interchangability of components

(ii) Easy accessibility to components for inspection & maintenance
5.0
CONSTRUCTION
5.1
The recepctle shall comprise single front panel, metal enclosed, dust & vermin
proof, floor mounted and free standing type. The frame shall be fabricated from
suitable mild steel sheets of thickness not less han 2.0 mm. The frames shall be
covered by cold-rolled steel sheets of thickness not less than 1.6 mm. Doors and
covers shall also be of cold rolled sheets of thickness not less than 1.6 mm.
5.2
The panel edges and cover / door edges shall be reinforced against distortion by
rolling, bending or by the addition of welded reinforcement members.
5.3
The complete structure shall be rigid, self-supporting, free from flaws, twists and
bends. All cutouts shall be true in shape and devoid of sharp edges.
5.4
The panels shall be provided with a degree of protection IP 55 .
5.5
The panel shall be supplied with base frames made of mild steel section
alongwith all necessary mounting hardware required for welding down the base
frame to the foundation / steel insert plates. The base frame height shall be such
that floor finishing (50 mm thick) after erection of the board does not obstruct the
movement of doors, covers, withdrawable modules etc.
5.6
The panel doors shall open by at least 90 degree .
5.7
All components in a panel shall be neatly arranged and easily accessible for
operation and maintenance.
5.8
The ON/OFF switches in a receptacle shall be rotary type, heavy duty, double
break, AC 23 category, suitable for AC supply.
5.9
Plug and socket shall be of shrouded die cast Aluminium. Sockets shall be
provided with lid safety cover.
5.10
Robust mechanical inter-lock shall be provided such that the switch can be put
ON only when the plug is fully engaged. Plug can be withdrawn only when the
switch is in OFF position. Additional inter-lock should be provided such that
covers can be opened only when the switch is in off position.
5.11
Wiring inside the receptacles shall be carried out with 1100 V grade PVC
insulated 6 Sq. mm stranded Aluminium conductor.
5.12
Terminal block in the receptacles shall be of 1100 V grade, clip on stud type,
moulded in Melamine, suitable for terminating specified cable size. All the
terminals shall be shrouded.
5.13
All wiring shall be properly supported, neatly arranged, readily accessible and
securely connected to equipment terminals and terminal blocks.
5.14
All wiring terminations shall be made with solderless crimping type tinned copper
lugs which shall firmly grip the conductor or an equally secured method.
Insulating sleeves shall be provided over the exposed parts of lugs to the extent
possible.
5.15
Receptacles shall include switches ,sockets & plugs mentioned as under:

230V, 20A, SP, 2 Pin
415V,20A, TP, 3 Pin
415V, 63A, TPN, 5 Pin
5.16 Galvanised steel earth bus shall be provided at the bottom welded / bolted to the
bottom of a panel.
5.17 The earth bus shall have sufficient cross section to carry the short time fault
current to earth, without exceeding the allowable temperature rise.
5.18 Suitable arrangement shall be made at each end of the earth bus for bolting to
earthing conductors. The earth bus shall be projected out of the panel ends and
shall have predrilled holes for this connection. All joint splices to earth bus shall
be made through atleast two bolts and taps by proper lug and bolts connection.
5.19 All non-current carrying metal work in a panel shall be effectively bonded to the
earth bus.
5.20 Name plates and labels
a) The receptacle shall be provided with prominent, engraved identification plates.
b) The name plates shall be of non rusting metal with white non graved letterings on
black back grounds. Inscriptions shall be subject to purchaser's approval .
c) Caution plate with the inscription " WARNING LIVE TERMINALS" shall be
provided on the front face of a receptacle. .
5.21
Painting
The sheet steel work shall be pre treated in accordance with relevant code .
Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed
by pickling with acid . After pickling phosphate coating of class C in accordance
with relevant code shall be provided. The phosphated surfaces shall be applied
with stove lead oxide primer coating followed by two coats of finishing synthetic
enamel paints. Electrostatic painting is also acceptable. Finishing paint on panels
shall be shade 692 (smoke grey) in accordance with relevant code . The inner
surface of the panels shall be glossy white. For electrostatic or powder painting
manufacturer's standard shade for inner surface of the panels shall also be
acceptable. Each coat of finishing paint shall be properly stoved. The finishing
paint thickness shall not be less than 50 microns. Finished surfaces shall be
coated by peelable compound by spraying method for protection against
scratches, grease, dirt & oil spots. All hardware shall be nickel chromium plated
or zinc passivated.

SPECIFICATION FOR LEAD ACID BATTERY
1.0
SCOPE :
This specification covers requirement for procuring, commissioning and
performance testing of lead acid battery for for control, indication, alarm and
protection circuit for each 6.6 kV switchboard located in Substation IV and VI.
Any material and component not specifically stated in this but necessary for
trouble free operation of the equipment and accessories specified herein shall
deemed to be included.
2.0
STANDARDS TO BE FOLLOWED :
2.1
The Battery shall be designed to comply with all applicable provision of current
Indian standards.
Where Indian Standards are not available, International Standards which ensure
performance equivalent or superior to Indian Standards shall be followed.
Nothing in this specification shall be construed as to relieve the supplier of the
All the standards being followed shall be listed out in the tender. Where any
foreign standard is being followed, the copy of the same shall be provided with
the tender.
Wherever service conditions and requirements laid down in this specification
differ from applicable standards, the conditions specified herein shall prevail.
2.2
The battery shall comply with all the latest applicable statutory rules, regulations,
acts and safety codes which may be in force during the period of execution and
which are related with design, construction and operation of equipment in the
locality where the equipment is to be installed.
The application acts and statutory regulations are as under :
a) Fire Insurance Regulation
b) Tariff Advisory committee Regulations
c) The Indian Electricity Act.
d) Indian Electricity rules
e) National Fire Code
f) DGMS Regulations
3.0
BATTERY
3.1
Three banks of 220 volts battery unit, one each for Substation IV, V and VI have
been envisaged. One bank of 220 V Battery unit along with associated charging
unit comprising of transformer, rectifier etc. shall be provided for control,
indication, alarm and protection circuit for each 6.6 kV switchboard located in
Substation IV and VI.
3.2
The D.C. voltage shall be obtained from 415V, three phase, 4 wire, 50 Hz, AC
supply after necessary rectification by the battery charger.
3.3
The battery charger shall have dual provision of :

i) Boost charging the battery
ii) Float charging the battery and supply the full DC load.
3.4
The battery shall be floating on the DC bus during the normal operation. The
battery shall supply the DC power during emergency operation i.e. during failure
of AC input power to the battery charger for atleast one hour. The battery shall be
of suitable rating to meet the requirement. The scope of design, supply and
installation also includes a suitable DC Distribution Board along with necessary
wiring, metering and protection arrangements.
3.5
Each unit shall also conform to the following specifications :

1 Set
: 220 Volts lead acid stationary battery, each consisting of

tubular sealed cells (each of 2 volts) in hard rubber boxes
complete with tubular positive plate, pasted negative plates,
lids, vent plug, acid level indicating floats, separators, bolts
and nuts, cell insulators, intercell connectors etc.
Capacity
: 160 AH when discharged in 10 hrs. to 1.85 volts per cell at

270C.
Trickle charge rate: Minimum 75 mA to maximum 300 mA to keep the cell at

2.25 to 2.30 volts.
1 set
: Connectors for the above battery.
1 Lot
: Sufficient quantity of sulphuric acid for the first filling

including spare acid 1.190 Sp. gr. at 270C suitably packed.
1 set
: Suitable battery stands made of good quality teak wood

finished with three coats of black anti-sulphuric paint and
complete with cell number plates and fixing nails.
3.6
The battery shall be maintenance free and complete with all accessories like
hydrometer, cell testing voltmeter, thermometer (glass type) with gravity
correction chart, spanner, glass funnel, Rubber siphon, Rubber Apron and gloves
etc.
3.7
TESTS :
The tenderer must ensure that the test mentioned in relevant BIS or Electricity
Rules have been performed.
ANNEXURE I
TECHNICAL PARAMETERS
a) Service
Indoor
b) No. required
1 Set having 110 nos. x 2 Volts each

for Sub-station-IV & VI.
c) Number of phases
Three phase
d) Frequency
50 Hz
e) Input supply
415V
f) Voltage variation in input supply
+ 10%
g) Frequency variation
+ 3%
h) Output nominal voltage
220V
i) Voltage regulation at output
+2%
j) Ripple without battery
+ 4% RMS
a discharged battery
8/10 Hours
l) Ambient temperature
500C
m)Relative humidity
100%
n) Cooling
Natural
k) Time required to complete charging

SPECIFICATION FOR CABLES
1.0
SPECIFICATION FOR XLPE INSULATED HT CABLES
1.1
SCOPE
1.1.1 This specification covers requirements for 6.6 kV grade XLPE insulated
Aluminium conductor HT cables.
1.1.2 The cable shall comply with the latest version of IS:7098 except where modified
or extended by this specification and with the relevant parts of standards
mentioned in clause 2.0.
1.1.3 Any material, component or accessory not specifically stated in this specification
but necessary for trouble free operation shall bne deemed to be included.
1.2
CODES
S : 10418
Specification of drums for electric cables
IS : 8130
Conductors for insulated electric cables and flexible cords
IS : 3975
Specification for mild steel wires, strips and tapes
IS : 10462
Fictitious calculation method for determination of dimensions of
protective covering of cables. Part I elastometric and thermoplastic
insulated cables
IS : 2
Rules for rounding off values
IS : 10810
Method of test for cables (Part 0 to Part 63)
IS : 1885
Electrotechnical vacabulary part 32, cables, conductors and
accessories
IS : 4905
Methods for random sampling.
1.3
CONSTRUCTION
1.3.1 Material
(a)
The conductor & insulation material shall be as under:

The conductor shall be Alumunium wires
The insulation used shall be Cross Linked Poly Ethylene compound .
(b)
The fillers and inner sheath shall be either of the following types :
Unvulcanized rubber
Thermoplastic material
Proofed tapes ( for inner sheath only)
The outer sheath shall be of Poly Vinyl Chloride (PVC) compound conforming to
the requirements of Type ST 1 compound .
Unvulcanized rubber or thermoplastic material used for filler and inner sheath
shall not be harder than PVC used for outer sheath. The material shall be chosen
to be compatible with the temperature rating of the cable (900 C) and shall have
no deleterious effect on any other component of the cable.
(c)
Armouring shall be either of the following types :

i)
Galvanised round steel wire
ii)
Galvanised steel strip
iii)
Galvanised steel wires/ ropes shall comply with the requirements of relevant
Code. A binder tape on the armour shall be provided.
1.3.2 Construnctional features

The conductor shall be of stranded construction complying with class 2 of
relevant code. A protective barrier shall be provided between the conductor and
the insulation and this shall be compatible with the insulating material and the
operating temperature of 900C.
The conductor with protective barrier shall be provided with XLPE insulation
applied by extrusion. Cables rated 6.6/11 kV shall be provided with conductor
screening and insulation screening.
The average thickness of insulation shall not be less than 3.6 mm, the tolerance
of thickness of insulation shall not fall below 0.46 mm.
Core identification shall be made by numerals (1,2,3) either by applying
numbered strips or by printing on the cores.
The cores with barriers shall be laid together with a suitable right hand lay.
Where necessary, the interstices shall be filled with non-hygroscopic material.
The laid-up cores shall be provided with inner sheath applied either by extrusion
or by wrapping.
It shall be ensured that the shape is as circular as possible
Inner sheath shall be so applied that it fits closely on the laid up cores and it shall
be possible to remove it while terminating a cable without damaging the
insulation.
The values of thickness of inner sheath shall not be less than 0.5 mm.
Armouring shall be provided over the inner sheath. The armour wires/strips shall
be applied as closely as practicable.
The direction of lay of the armour shall be left hand. A binder tape may be
provided on the armour.
The nominal thickness of steel strips shall not be less than 1.4 mm and the
nominal diameter of round armour wire shall not be less than 4 mm.
The joints in armour wires or strips shall be made by brazing or welding and any
surface irregularities shall be removed. A joint in any wire/strip shall be at least
300 mm from the nearest joint in any other wire or strip in the complete cable.
The outer sheath shall be applied by extrusion over the armouring.
The colour of the outer sheath shall be black. The thickness of outer sheath shall
be not less than 3 mm.
2.0
SPECIFICATION FOR 660/1100 V GRADE PVC ARMOURED CABLE
2.1
SCOPE
2.1.1 This specification covers requirements for 660 V/1.1 kV grade PVC insulated
(Heavy duty)Armoured Aluminium conductor electric cables.
2.1.2 The cable shall comply with the latest version of IS:1554 (Part 1) except where
2.2
CODES
IS : 10418 : Specification of drums for electric cables
IS : 8130
: Conductors for insulated electric cables and flexible cords
IS : 3975
: Specification for mild steel wires, strips and tapes
IS : 5831
: PVC insulation for armouring cables and sheath of electric cables
IS : 10462 : Fictitious calculation method for determination of dimensions of
insulated cables
IS : 2
: Rules for rounding off values
IS : 10810 : Method of test for cables (Part 0 to Part 63)
IS : 1885
: Electrotechnical vacabulary part 32, cables, conductors and
accessories
IS : 4905
: Methods for random sampling.
2.3
CONSTRUCTION
2.3.1 Material
(a)
The conductor and materials shall be as under:

The conductor shall be Alumunium wires conforming to relevant codes.
The insulation used shall be Poly Vinyl Chloride (PVC) compound conforming to
the requirements of Type A and Type C compound conforming to relevant codes.
(b)
Unvulcanized rubber or
the requirements of Type ST 1 compound conforming to relevant codes.
shall not be harder than PVC used for insulation and for outer sheath. The
material shall be chosen to be compatible with the temperature rating of the
cable (700 C) and shall have no deleterious effect on any other component of the
cable.
(c)

i) Galvanised round steel wire
ii) Galvanised steel strip
The Galvanised steel wires/ ropes shall comply with the requirements of relevant

relevant codes. A protective barrier shall be provided between the conductor and
The conductor with protective barrier shall be provided with PVC insulation
applied by extrusion.
The average thickness of insulation shall not be less than 1 mm to 2.4 mm
depending upon the nominal area of the conductor. The tolerance of thickness of
insulation shall be such that the smallest of measured values of thickness of
insulation shall not fall below 0.2 mm to 0.34 mm respectively.
Core identification shall be made by colour scheme of PVC insulation by
adopting the following :
3 Core
Red, Yellow, Blue
31/2 Core or 4 Core
Red, Yellow, Blue, Black
The outer most layer of the cores shall be laid together with a suitable right hand
lay and successive layers shall be laid with opposite lay. Where necessary, the
interstices shall be filled with non-hygroscopic material.
The laid up cores shall be provided with inner sheath applied either by extrusion
or by wrapping.
insulation.
The values of thickness of inner sheath shall not be less than 0.4 mm to 0.7 mm
depending the nominal area of the conductor.
Armouring shall be provided over the inner sheath.

The armour wires/strips shall be applied as closely as practicable.
The direction of lay of the armour shall be left hand.
A binder tape may be provided on the armour. The armour of the cables shall
consists of either galvanized round steel wires or galvanized steel strips.
The nominal thickness of steel strips shall be between 0.8 mm to 1.4 mm and the
nominal diameter of round armour wire shall be between 1.6 mm to 4 mm.
The outer sheath shall be applied by extrusion over the armouring. The colour of
the outer sheath shall be black. The thickness of outer sheath shall be between
1.4 mm to 3 mm depending upon the nominal area of the conductor.
3.0
SPECIFICATION FOR 660 /1100 V GRADE UNARMOURED CABLE
3.1
SCOPE
unarmoured Aluminium conductor electric cables for power supply to light & fan
circuits.
3.1.2 The cable shall comply with the latest version of IS:694 except where modified or
extended by this specification and with the relevant parts of standards mentioned
in clause 2.0.
3.2
CODE
IS : 3961
Recommended current ratings for PVC insulated cables
IS : 5831
PVC insulation and sheath of electric cables
IS : 8130
Conductors for insulated electric cables and flexible cables
IS : 10810 Methods of tests for cables
3.3
CONSTRUCTION
3.3.1 Material
(a)

The conductor shall be Alumunium wires conforming to relevant codes.
the requirements of Type A compound conforming to relevant codes.
(b)
vulcanized rubber
Unvulcanized rubber
The filler material shall be suitable for continuous operation without exceeding
700 C & compatible with other components of the cable. Unvulcanized rubber or
thermoplastic material used for filler shall not be harder than PVC used for
insulation and sheath .
3.3.2 Conductor
(a) The construction of the conductors shall be for fixed wiring. Conductors shall be
circular .
(b) The construction of the conductors shall be stranded only .
(c) The conductor shall be provided with PVC insulation applied by extrusion. The
insulation shall be so applied that it fits closely on the conductor and it shall be
possible to remove it without damage to the conductor. The thickness of the
insulation shall be between 0.7 to 1 mm .
(d) The cores shall be identified by different colouring of PVC insulation, such as
Red & Black .
(e) The cables shall have two cores laid side by side in the same plane with a
suitable right hand lay.
(f) The sheath shall be applied by extrusion. It shall be applied over the laid up
cores fitting closely. It shall be possible to remove the sheath without damage to
the sheath. The colour of the sheath shall be Black. The thickness of the sheath
shall be between 0.9 to 1.4 mm .
4.0
SPECIFICATION FOR 660/1100 V GRADE CONTROL CABLE
4.1
SCOPE
Armoured copper conductor control cables.
4.1.2 The cable shall comply with the latest version of IS:1554 (Part 1) except where
4.2
CODES
IS : 10418 : Specification of drums for electric cables
IS : 8130
IS : 3975
IS : 5831
IS : 10462
IS : 2
IS : 10810
IS : 1885
IS : 4905
: Conductors for insulated electric cables and flexible cords

: Specification for mild steel wires, strips and tapes
: PVC insulation for armouring cables and sheath of electric cables
: Fictitious calculation method for determination of dimensions of
insulated cables
: Rules for rounding off values
: Method of test for cables (Part 0 to Part 63)
: Electrotechnical vacabulary part 32, cables, conductors and
accessories
: Methods for random sampling.
4.3
CONSTRUCTION
4.3.1
Material
(a)

The conductor shall be Copper wires conforming to relevant codes.
the requirements of Type A and Type C compound conforming to relevant codes.
(b)
Unvulcanized rubber or
the requirements of Type ST 1 compound conforming to relevant codes.
shall not be harder than PVC used for insulation and for outer sheath. The
material shall be chosen to be compatible with the temperature rating of the
cable (700 C) and shall have no deleterious effect on any other component of the
cable.
(c)

a) Galvanised round steel wire
b) Galvanised steel strip
The Galvanised steel wires/ ropes shall comply with the requirements of relevant

relevant codes. A protective barrier shall be provided between the conductor and
The conductor with protective barrier shall be provided with PVC insulation
applied by extrusion.
The average thickness of insulation shall not be less than 0.8 mm to 0.9 mm
depending upon the nominal area of the conductor. The tolerance of thickness of
insulation shall be such that the smallest of measured values of thickness of
insulation shall not fall below 0.18 mm to 0.19 mm respectively.
Core identification shall be made by colour scheme of PVC insulation by
adopting the following :
2 Core
Red, Black
3 Core
Red, Yellow, Blue
4 Core
Red, Yellow, Blue, Black
5 Core
Red, Yellow, Blue, Black, Grey
6 Core & above
Two adjacent cores (counting and direction core)

in each layer, blue and yellow, remaining cores
grey, or the core identification may be done by
numbers. In that case, the insulation of cores shall
be of the same colour and numbered sequentially,
starting with number 1for the inner layer. All the
numbers shall be of the same colour which shall
contrast with the colour of the insulation. The
numerals shall be legible.
The outer most layer of the cores shall be laid together with a suitable right hand
lay and successive layers shall be laid with opposite lay. Where necessary, the
interstices shall be filled with non-hygroscopic material.
The laid up cores shall be provided with inner sheath applied either by extrusion
or by wrapping.
insulation.
The values of thickness of inner sheath shall not be less than 0.3 mm.
Armouring shall be provided over the inner sheath.
The armour wires/strips shall be applied as closely as practicable.
The direction of lay of the armour shall be left hand.
A binder tape may be provided on the armour. The armour of the cables shall
consists of either galvanized round steel wires or galvanized steel strips.
The nominal thickness of steel strips shall be between 0.8 mm to 1.4 mm and the
nominal diameter of round armour wire shall be between 1.4 mm to 4 mm.
The outer sheath shall be applied by extrusion over the armouring. The colour of
the outer sheath shall be black. The minimum thickness of outer sheath shall be
1.24 mm.
5.0
FLEXIBLE TRAILING CABLES

Flexible Trailing cables shall be 6.6 kV/1.1 kV grade, 4 core flexible Trailing
annealed tinned stranded copper conductor, EPR insulated, EPR inner sheathed,
GI wire braid armoured and CSP outer sheathed cables conforming to IS :
14494.
6.0
SPECIAL CABLES
Special cables shall be provided including but not limited to the following:
a) Temperature detectors from HT motors to the selector switches,
b) Level indicators from coal bunker level, Silo level
c) Temperature detectors to associated electronic enclosure, etc.
These cables shall be heavy duty fire retarding self extinguishing, colour
coded, shielded, armoured copper conductor 650/1100 volts grade coaxial
screwed compensating mineral insulated etc.
7.0
PERFORMANCE
The cables shall carry the rated current for the type of installation and ambient
temperature in accordance with the relevant Code. The cable shall also be able
to withstand the fault level in accordance with the relevant Code.
8.0
TESTS & CERTIFICATES & IDENTIFICATION

The cable shall be tested in accordance with relevant codes.Results of Routine
tests for High voltage test and Conductor resistance test and Bending test shall
be supplied by the manufacturer before the consignment of the cable. The
purchaser reserves the right to conduct Acceptance tests preceeded by sampling
in accordance with relevant codes. The results of the test certificate shall also
indicate the identifications like manufacturer's name or trade mark, the voltage
grade, year of manufacture. These identifications shall also appear printed or
embossed on the outer sheath .
9.0
PACKING & MARKING

The cables shall be supplied on a drum of suitable size and packed in
accordance with the provisions of relevant codes. The ends of the cable shall be
sealed by means of non hygroscopic sealing compound .
ANNEXURE I
TECHNICAL INFORMATION FOR XLPE INSULATED HT CABLES
Applicable Code
- IS 7098
Cable Code
- A2XFY/2XFY
Voltage Grade
-6.6 KV
Conductor Size
- As required
No. of Cores
- Three
TECHNICAL INFORMATION FOR 660/1100 V GRADE PVC ARMOURED
CABLE
Applicable Code
IS 1554 (Part-1)
Cable Code
AYFY
Voltage Grade
660/1100 V
Conductor Size
As required
No. of Cores
3/3.5/4
TECHNICAL INFORMATION 660 /1100 V GRADE UNARMOURED CABLE
Applicable Code
- IS 694
Cable Code
- AYY
Voltage Grade
- 660/1100 V
Conductor Size
- As required
No. of Cores
- Two/Three/Four
TECHNICAL INFORMATION FOR 660/1100 V GRADE CONTROL CABLE
Applicable Code
IS 1554 (Part-1)
Cable Code
YWY/YFY
Voltage Grade
660/1100 V
Conductor Size
1.5/2.5 mm2
No. of Cores
As required

SPECIFICATION FOR ACCESSORIES OF CABLING
1.0
SCOPE
1.1
This covers requirements for accessories of cabling work like cable trays, cable
ladders, PVC & Steel conduits and fittings, support systems.
1.2

1.3
Nothing in this specification shall be construed as to relieve the bidder of the

2.0
CODE
The applicable codes are as under :
IS 732
Code of practice for electrical wiring
IS 513
Cold rolled low carbon steel and strips .
IS 1079
Hot rolled carbon steel and strips .
IS 9537
Conduits for electrical installation
IS 2667
Fittings for rigid steel conduits for electrical wiring .
IS 8309
Compression type tubular terminal ends for Aluminium
conductors of insulated cables .
IS 2629
Recommended practice for hot dip galvanizing .
IS 2633
Methods for testing uniformity of coating of Zinc coated articles .
IS 1367
Technical supply conditions for threaded steel fasteners .
IS 1663
Method for tensile testing of steel sheet & strip of thickness
0.5 mm to 3 mm .
3.0
CONSTRUCTION
3.1
Cable trays, fittings and accessories
i)
In RCC trenches, the cable trays shall be of cantilever construnction, with one or
multi tiers complete with matching fittings (like elbows, bends, reducers, tees,
crosses, etc.), accessories (like side coupler plates etc.) and hardware (like bolts,
nuts, springs, washers, etc.) as may be required. In vertical sections the trays
shall be of ladder construnction with one or multi tiers complete with matching
fittings (like elbows, bends, reducers, tees, crosses etc.), accessories (like side
coupler plates etc.) and hardware (like bolts, nuts, springs, washers, etc.) as may
be required.
ii)
Cable trays, fittings and accessories shall be fabricated out of rolled Mild Steel
sheets free from flaws such as laminations, rolling marks, pitting etc. conforming
to relevant codes. Minimum thickness of Mild Steel sheets used for fabrication of
cable trays and fittings shall be 2mm. The thickness of side coupler plates shall
be minimum 3 mm. These shall be hot dip galvanized.
iii)
Cable trays in the RCC trenches shall be of standard width 250 mm and of
standard lengths 2.5 metre. Cable ladders shall be of widths varying between
150 to 250 mm and of standard lengths 2.5 metre.
iv)
Each size and type of cable tray / ladder of 2.5 metre length and 250 mm width
simply supported at the ends and uniformly loaded @ 76 kg. per metre shall not
have deflection at the mid span exceeding 7 mm.
3.2
Support System for Trays and Cables

The support system shall be fabricated from standard structural steel members.
The cable trays and support system shall be painted after installation with one
coat of red lead primer, one coat of oil primer followed by two finishing coats of
Aluminium paint .
3.3
Conduits , Fittings and Accessories

Conduits offered shall be rigid steel & PVC complete with fittings and accessories
(like bends, check nuts, sockets etc.). The size of the conduit shall be selected
on the basis of maximum 40% fill factor and in accordance with relevant code .
i)
Rigid Steel Conduits

Rigid steel conduits conforming to relevant codes shall be threaded on both sides
and suitable for mechanical stresses. The threaded length shall be protected by
zinc rich. Conduits shall be smooth at inside and outside. It shall be possible to
pass wooden ball in a straight length of conduit. Diameter of ball shall be 2 mm
less than the internal diameter of conduit. Conduits shall be plugged by PVC
caps at the ends for storage and transportation. Outer surface of conduit shall be
hot dip galvanized and shall have high protection against corrosive and polluting
substances. Supplementary polymer or synthetic coating shall be preferred.
However, galvanising or pollution withstand tests shall be done after removal of
supplementary coating. Inner surface of a conduit shall be protected against
corrosion and polluting substances by hot dip galvanising. Galvanising tests as
per relevant codes to withstand four nos of dips each of one minute duration in
CuSO4 solution shall be done. Fittings and accessories shall also be hot dip
galvanised.
i)
Junction / Joint Boxes & power recepctecles circuits

Junction Box/cable joint boxes with IP:55 degree of protection, shall comprise a
case and a detachable cover or hinged doors constructed out of cold rolled
steel sheet of minimum thickness 2 mm. Top of the boxes shall be arrnaged to
slope towards rear of the box. Gland plate shall be 3 mm thick sheet steel with
neoprene/synthetic rubber gaskets. All junction boxes shall be of adequate
strength and rigidity, hot dip galvanised, and suitable for mounting on walls,
columns & structures. The boxes shall include brackets, bolts, nuts, screws,
glands, lugs, M8 earthing stud required for erection. Terminal blocks in side a
junction box shall be of 660 volts grade in one piece moulding. It shall be
complete with insulating barriers, clip-on-type terminal numbering for wiring

diagrams & arranged to facilitate easy termination. Twenty percent spare
terminals shall be provided in each terminal block.
iii)
Cabling Accessories:
a) Cable Glands :
Cable glands shall be single compression type suitable for the voltage grade of
cables and as per relevant codes. The glands shall be of robust construction
capable of clamping cable and cable armour (for armoured cables) firmly without
injury to insulation. The glands shall be heavy duty brass, machine finished and
nickel chrome plated of minimum 10 micron thickness. All washers and
hardware shall be made of brass with nickel chrome plating. Rubber
components shall be of neoprene and of tested quality.
b) Cable Lugs :
Cable lugs shall be tinned copper solder or crimping type suitable for the voltage
grade of cables suitable for Aluminium conductor cables and copper conductor
control cables.
c) Galvanising
Galvanising of steel components and accessories shall conform to relevant
codes. The galvanising shall be uniform, clean, smooth, continuous and free
from acid spots. Should the galvanizing of the samples be found defective, the
entire batch of steel shall have to be re-galvanised at contractor's cost after
pickling.
. The amount of zinc deposit over threaded portion of bolts, nuts, screws and
washers shall be as per relevant codes. The removal of extra zinc on threaded
portion of components shall be carefully done to ensure that the threads have
the required zinc coating on them.
d) Painting
Cable supports and cable trays mounting structures and all other non
galvanized parts shall be brushed before giving one coat of red lead primer, one
coat of oil primer followed by two finishing coats of Aluminium paint.

SPECIFICATION FOR STEEL TUBULAR POLES FOR LIGHTING
1.0
SCOPE
1.1
This specification covers requirements for swagged type steel tubular poles for
outdoor lighting.
1.2
The poles shall comply with the requirements of IS : 2713 except where modified
or extended by this specification and with the relevant part or standards
mentioned in clause 2.0.
1.3

2.0

IS:209
- Specification of Zinc
IS :2633 - Method of testing weight, thickness, and uniformity of coating
on hard dipped, galvanising articles.
IS : 728 - Method on determination of weight, thickness and uniformity of
coating on galvanised articles other than wires & sheets.
IS : 1573 - Specification for zinc plating
IS :5
- Colour for ready mixed paints and enamels.
3.0
CONSTRUCTION
3.1
The tubular poles shall consist of 3 or 4 sections of dimensions conforming to the

relevant standard.
3.2
The thickness of the steel sheets shall conform to the relevant standards.
3.3
The section shall be hard dip galvanised in accordance with the relevant
standards.
3.4
The section shall be applied with 2 coats of primer and one coat of final paint in
accordance with the relevant standards.
3.5
In case of swan neck pole, top section shall be curved in accordance with the
drawing enclosed. The lamp fixture shall freely fit in with the coupler. For other
type of poles, the lamp fixture mounted on a bracket clamped on the pole at a
height of not less than 7 m from the road surface and projecting at least 1.3 m
into the road from the centre of the pole.
3.6
The lower most section shall be provided with a base plate having holes for firm
fixation in the foundation. The height of the pole shall be 9 m.
The bidder/supplier shall submit the dimensioned drawings for different sections
for approval by Purchaser before fabrication.

SPECIFICATION FOR MASTS FOR LIGHTING
1.0
SCOPE
This specification covers requirements for high masts for outdoor lighting with
street light/flood light fixtures.
2.0
CONSTRUCTION
The mast shall comprise the following components :
2.1
The mast shall comprise sections of over 6 metre length. Each section shall be
made of steel complying with I.S. 226 of appropriate grade, polygonal section,
telescopic jointed and fillet welded with the exception of site joints. The welding
shall be in accordance with B.S. 5135. Each section shall include one telescopic
and welded joint which provides diaphragm stiffness to maintain the structural
strength during delivery and in service. The whole mast shall be continuously
tapered. A door shall be provided at the base of the mast to permit clear access
to winch assembly and power supply sockets. The door shall be weather
resistant with a heavy duty lock. The base flange of welded construction shall
provide full strength to the mast assembly. The mast shall be delivered to site in
sections and joined with sleeve joints. No welded or bolted joints shall be
allowed.
2.2
The foundation shall be provided by anchor plates with high tensile bolts.
2.3
The entire mast section shall be hot dip galvanised in accordance with I.S. 2629.
Each section shall be given two coats of primer and one coat of final paint in
accordance with shade 631 of I.S. 5.
2.4
For installation and maintenance of the top luminaire assembly a winch shall be
provided at the base of the mast. The winch shall be completely self sustaining
without the need for brakes, springs, or clutches which require adjustment. The
winch shall have one or more drums corresponding to number of steel ropes
required for suspension of the top luminaire assembly. The drums shall be
suitably grooved ensuring tidy rope lay and smooth return of the rope for each
lay. At least 4 turns of rope shall remain on a drum when the top luminaire
assembly is fully lowered.
The winch shall be manually operable and also by power tools incorporating two
speed reversible 240 volt single phase 50 Hz AC/DC universal motor coupled by
a gear assembly of adequate ratio. The driving spindle shall be positively locked
when not in use by a suitable automatic means. The winch shall be self
lubricated by an oil bath. The capacity, the operating speed and the
recommended lubricant shall be clearly marked on each winch with an indelible

label. Each winch shall be supplied in waterproof enclosure.
2.5
Separate pulleys shall be mounted on a chassis integral with a sleeve which slips
over the top of the mast axially and in azimuth. The pulleys made of noncorrodible material and run on self lubricating bearings with stainless steel
spindles shall take on steel wire ropes and electric cables on suitable grooves.
Suitable guides and stops shall be provided for the steel wire ropes for correct
guiding of the luminaire assembly. The pulley assembly along with chassis shall
be hot dip galvanised in accordance with relevant code aforesaid. The assembly
shall be supplied in a weatherproof enclosure.
2.6
Suitable steel wire ropes of the stainless type shall be provided.
2.7
Stainless steel stud of diameter not less than 12 mm shall be attached to the
mast structure at a convenient point within the base compartment to provide a
earthing point.
2.8
The luminaire assembly shall consist of radial steel conduits for cables supplying
power to fixtures. The assembly shall have fixing arms and plates for mounting
junction boxes.Junction boxes in two separable halves shall provid supply of
power to different fixtures. The assembly shall be provided with buffer
arrangements to prevent damage to the mast finish.
2.9
Multicore flexible power cables shall be terminated on metal cased plug and
sockets in the base compartment of the mast. At the mast head cables shall be
connected to the weather proof junction box aforesaid with nylon glands.
2.10
Extension leads of multicore cables shall be provided with plug and socket to
enable the fixtures to be tested when in the lower most position using base
compartment socket supply.
ANNEXURE -I
TECHNICAL INFORMATION
1
Height of mast
: 14 M/18M/25M/30M
Ground level diameter
: 300 mm/386 mm/ 440 mm/610 mm
Top section diameter
: 100mm/100mm/150mm/150 mm
Maximum projected area of

luminairs
: 0.8 sq.metre/0.8 sq.metre/

0.9 sq.metre/2.8 sq. metre
Maximum weight of the

luminaire assembly
: 150 kg/150 kg/350 kg/350 kg
Number of sections
: 2/2/3/3
Length of longest section
: not exceeding 11 metres
Luminaire assembly
This shall comprise :
a) High mast street light fixtures with aluminium body, integral control
gear, lamp holder and variable optic reflector. The fixture shall be of
IP 54 construction and suitable for mounting 400 watt HPSV lamp.
b) Flood light fixture with aluminium body, integral control gear, lamp
holder and cradle with fixture adjuster. The unit shall be of IP 54
construction and suitable for mounting 400 watt HPSV and 1000 watt
Tungsten Halogen lamps.

SPECIFICATION FOR MISCELLANEOUS ITEMS
The following general requirements shall be applicable to all the miscellaneous
items furnished under these specifications.
1.
Emergency Power Supply

For emergency power supply the following shall be provided :
a)
Air cooled type generator.
b)
Auto-cum-Manual starting of generator in case of power failure.
c)
Separate wiring should be provided from generator to strategic locations.
d)
Additional emergency lights shall be provided to other locations as per direction of

site engineer, if felt necessary, within the maximum load of 5 kW.
e)
Inverter emergency lights shall be provided in all sub-stations and silo loading
complex.
f)
For emergency light, minimum requirement of illumination level shall be 10 Lux.

However, actual requirement shall be worked out by bidder.
2.0
Conveyor Accessories
2.1
Pull Cord Switches

Pull chord operated emergency stop switches shall be provided in one side along
the entire length of conveyors at a spacing of 50 metres for emergency stopping of
the conveyor. The switches shall be hand reset type, having a resetting lever. At
least one Pull Cord Switch shall be provided for small conveyors. It shall be
cast/metal clad and shall have weather proof enclosure. The pull chord shall be of
adequate length and shall be of standard flexible galvanised wire. Pull chord switch
shall also have operating signal facility.
2.2
Belt Sway switch

These switches shall be auto reset, double contact type, one for advance
indication of escessive belt sway and the other for tripping the conveyor. The
switch shall be complete with roller, levers, arm etc. and painted with anti corrosive
paint. These switches shall be provided at a spacing of 50 metres. Minimum 4 nos.
switches shall be provided for each conveyor i.e. 2 nos. at head end and 2 nos. at
tail end of conveyor. It shall be provided with common bridging by-pass switch at
the central desk which may be required to be used during starting and also during
emergency.
2.3
Zero speed switch

These switches shall be electro-dynamic type. It shall be provided to trip the
conveyor in case of belt speed falling below 80% of the rated speed. These
switches shall also serve as belt sequence switches for the preceeding conveyor.
These switches shall have 1 NO & 1 NC change over contact. Zero speed
switches shall be provided at the tail and/or preferably on drive end of each
conveyor to keep the operational speed within a set limit. It shall have cast/metal
clad dust and weather proof enclosure.
3.0
Pressurisation and Air conditioning

All the Sub-station buildings in CHP shall be pressurised from inside to prevent
dust entry. All control rooms shall be air conditioned using required numbers of
window type air conditioners each having capacity of 1.5 Te. MCC rooms, control
rooms (including control room for substations shall be pressurised with
conditioning of inlet air (no. of air changes not less than 15) and humidity shall be
controlled to ensure proper working of equipment and operating personnel inside
the room. Requisite number of exhaust fans and ceiling fans shall be provided in
rooms to ensure proper working conditions for equipment and personnel in the
rooms in case of failure of pressurisation and air conditioning equipment.
4.0
Metal Enclosed Non-segregated Phase Bus Duct
4.1
Metal enclosed non-segregated phase bus duct assemblies shall be supplied for
incoming connection from the transformers to MCCs.
The enclosure shall be made of aluminium alloy. The section of the bus duct shall
be rectangular. The design of the bus duct enclosure shall be of sturdy
construction such that it will withstand the internal or external forces resulting from
the various operating conditions. The enclosure sheet thickness shall not be less
than 3 mm.
The entire duct shall be designed for dust, vermin and weatherproof construction.
A suitable aluminium sheet hood shall be provided to cover all outdoor bus duct
enclosure joints to facilitate additional protection against rainwater ingress. Bus
duct enclosure in the indoor portion shall have a degree of protection not less than
IP-52 and that in the outdoor portion shall have a protection not less than IP-55
accordance with IS 2147.
The inside of the bus enclosure shall be treated with black paint to enable efficient
heat dissipation. The matt paint used shall be suitable for temperature experienced
during continuous loading of the bus conductor.
Flexible expansion joints for the enclosure shall be provided wherever deemed
necessary by the Bidder. Necessary bonding shall be provided at the expansion
points if made of insulating material.
Enclosures shall be provided with flanged ends with drilling dimensions to suit the
flanges at the switchgear and transformer terminals. The flanges shall be provided
with gaskets, nuts, bolts, etc. Details of the flanges provided on
transformer/switchgear ends shall be properly co-ordinated with bus duct
Contractor.
Suitable inspection covers shall be provided for periodic inspection of insulators.

Handles shall be provided on each inspection cover to facilitate easy lifting.
Synthetic/neoprene gasket shall be provided so as to satisfy the operating
conditions imposed by temperature, weathering, durability etc. Flange gasket shall
be provided at the equipment terminal connections.
Bus duct enclosure shall be connected to station earth grid at both ends.
Necessary earthing arrangement as applicable shall be provided with clamps to
receive station earthing bus. All accessories and hardware required for the
earthing arrangement shall be provided by the bidder. Suitably rated GI earth strip
shall run all along the bus duct and shall be bolted to each section of bus duct
enclosure at least at two places.
4.2
Busbar
The material of the conductor shall be aluminium. The busbars shall be rated in
accordance with the service conditions and the rated continuous and short time
current ratings as specified.
Busbars shall be adequately supported on insulator to withstand dynamic stresses
due to short circuit current specified, without permanent deformation. Successful
bidder shall furnish calculations establishing adequacy of busbar for specified
current rating during detailed design.
All busbar joints and bus tap joints shall be either silver faced or thoroughly
cleaned at the joints, and a suitable no oxide contact grease applied before making
a joint. Plain and spring washers shall be provided to ensure good contacts at the
joints and lamps.
Flexible connections for terminations at transformer bushing and switchgear shall
also be included in the bidders scope of supply.
Expansion joints made of aluminium strips shall be provided, wherever felt
necessary by the bidder, to take care of expansion and contraction of the busbars
under normal operating conditions.
All the joints shall be tested for temperature rise to establish the adequacy of
design. The maximum temperature rise at the joints when carrying rated current
shall not exceed 55oC with silver plated joints and 40oC with all other type of joints,
over an outside ambient 50oC.
The busbar clamps at insulators shall be designed to withstand the forces due to
momentary circuit current the busbars during expansion and contraction. The
material of the clamps shall be aluminium alloy. Suitable aluminium spacers shall
be provided, wherever necessary.
All bolts, nuts and lock washers used in the bus assembly shall be of high tensile
steel, plated for corrosion resistance. Spring washers/Belleville washers shall be
used.
Busbar support insulators shall be made of non hygroscopic non combustible,

track resistant and high strength type porcelain or polyester fibre glass mounted
material and shall be suitable to withstand the dynamic stress due to specified
short circuit currents.
Facility shall be provided for supporting the indoor bus duct from ceiling, floors or
beams. The outdoor bus ducts shall be supported from the floor by T-shaped steel
structures.
All steel structures required for bus duct support shall be hot dip galvanised.
4.3
Bus Duct space Heaters

Space heaters shall be provided in the bus ducts, wherever the manufacturer
considers necessary and recommends their provision for preventing harmful
moisture condensation.
The space heaters shall be suitable for continuous operation on 240V AC, 50 Hz,
single phase supply, and shall be automatically controlled by thermostats.
5.0 FIRE FIGHTING EQUIPMENT :

The switch-gear rooms in the sub-stations and all strategic points shall be provided
with fire fighting equipment of the following class :
Class B (Foam type)
: IS : 933
Class A (Soda Acid)
: IS : 934
Class BC (Dry Powder)
: IS : 933
The equipment shall be portable, wall mounted with refilling and recharging facility
from time to time.
6.0 MISCELLANEOUS:
6.1 Painting :
All electrical equipment should be painted with air drying synthetic enamel paint in
accordance with respective manufacturer's standard practice.
6.2 Standards :
The electrical equipment included in this tender shall comply with relevant IS
specifications and IS code of practice. In the absence of IS, BS any other standard
of repute shall be followed.
6.3 Tests:
The offer shall include all test certificates as required by ISS and Indian Electricity
Rules.
6.4 Tools & Tackles:
Tenderers shall quote separate price for standard tools and tackles required for
maintenance of the electrical equipment. This shall also include the necessary
measuring instruments, rubber mats & gloves etc.
6.5 Fitting & Spares :

All standard fittings should be provided. The tenderer shall quote item-wise unit
price for spare parts.
6.6 Two years fast moving spares :
Tenderers shall also furnish the list of two years fast moving spares along with
their prices separately.
6.7 Technical Particulars :
The supplier shall furnish the technical particulars duly filled as given elsewhere.
6.8 Guarantee :
All the supplies should be guaranteed for a period of one year from the date of
installation and commissioning.
6.9 Deviations :
Deviations if any, from these specifications shall be clearly indicated in the offer.
6.10 Completeness of Offer :
The details given in the write-up/specifications (including drawings) in respect of
electrical system/equipment are indicative, not exhaustive. The electrical
system/equipment shall co-ordinate with mechanical system/equipment of the
plant.
If any electrical component or equipment with associated wiring is considered
necessary and desirable as per Indian Electricity Rules amended up to date read
with various circulars issued by the Director General of Mines Safety, Dhanbad, or
if the same is considered necessary and desirable to comply with the up-to-date
engineering practices or with various Indian codes of Practices issued by the I.S.I.
New Delhi from time to time the same shall be deemed to be a requirement of this
tender specifications and same should consequently included in the offer not-withstanding the fact that such requirements are not clearly or specifically indicated in
these specifications along with the associated drawings.
All the equipment attachments, required for the execution of works as per scope of
work as envisaged in the document shall be designed, fabricated erected and
maintained for efficient and satisfactory performance, and the bidder shall be solely
responsible for the same and the same shall be deemed to be within the scope of
the offer/work whether specifically mentioned or not in these documents and the
bidder shall not be eligible for any extra claim on this issue.

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Tender Document for Nigahi CHP Phase-II (Package A)

Specification No. SP/E-17

OTHER RELEVANT STANDARDS

Vol-II / Sec.-IV.2 / Page - 143

Tender Document for Nigahi CHP Phase-II (Package A)

Upto 1000 M above MSL.

Degree 4 as per IS : 13947 (Part I)

Bus bar system

Miniature/Residual Current Circuit Breakers and Distribution Boards

Vol-II / Sec.-IV.2 / Page - 144

Tender Document for Nigahi CHP Phase-II (Package A)

: 240 V for SPN / SP

Enclosure of the breakers

: Moulded self extinguishing thermoset

Dolly (Switching lever)

: Can be locked in either (Off or On

Auxiliary contact poles (for

: 240V 5A, A.C. (Optional).

: 25 mm2 conductors for phase and 16

12 Mechanical service life

: Not less than 20,000 operations.

13 Electrical endurance at rated

: Not less than 20,000 operations.

Vol-II / Sec.-IV.2 / Page - 145

Tender Document for Nigahi CHP Phase-II (Package A)

Bus current carrying capacity

: 2 mm thick CRCA sheets.

: 4 ways / 8 ways / 12 ways / 16 ways.

: Channel mounted / Flush top cover.

: Top / Bottom cable entry conduits.

: IP 42 (Metallic double door) degree of

: Powder coated finish.

: Pad locking facility.

: Shrouded type integral single piece bus

Vol-II / Sec.-IV.2 / Page - 146

Tender Document for Nigahi CHP Phase-II (Package A)

Specification No. SP/E-18

3-Pin, plug and socket outlets

Switches for domestic and similar purposes

PVC unarmoured 660 V grade cable

Boxes for enclosure of electrical accessories - Steel and cast iron

Low voltage fuses

Vol-II / Sec.-IV.2 / Page - 147

Tender Document for Nigahi CHP Phase-II (Package A)

No of 5A piano key switches

No of 5/15A , 3/5 pin socket with 15A

No of fan regulators (electronic)

Rewirable fuse 5A with base

1.6 mm thick MS sheet

with 660 V grade by 1.5 Sq mm

Two terminals shall be provided

Vol-II / Sec.-IV.2 / Page - 148

Tender Document for Nigahi CHP Phase-II (Package A)

Specification No. SP/E-19

This specification covers requirement for fixtures of tubular fluorescent lamps,

Any material, component or accessory not specifically stated in this specification

OTHER RELEVANT STANDARDS

The other standards applicable are as under :

Fluorescent lamp fixtures

Tender Document for Nigahi CHP Phase-II (Package A)

moulded in white thermoplastic compound shall be supported below the channel

High bay/Medium bay fixtures for Vapour lamps.

Vol-II / Sec.-IV.2 / Page - 150